Insert for a female plug coupling for an electric connector plug

ABSTRACT

A female plug coupling having three plug openings to accommodate the current conductors and the ground conductor of a male plug coupling. The female plug coupling includes an insert constructed whereby all the crimp connections lie in a single plane to facilitate crimping on the conductor ends to the female plug coupling.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application is a National Stage Application under 35 U.S.C.§371, of PCT International Patent Application Number PCT/EP99/06895,(published as International Publication Number WO 00/21162), filed Sep.17, 1999, that designated the United States, which stems from GermanApplication No. 198 47 067.3, filed Oct. 6, 1998.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a female plug coupling having threeplug openings. More particularly, the present invention relates to animproved insert for a female plug coupling having three plug openings.

2. Description of the Related Art

Such plug couplings are in use in the USA and Japanese markets. Forexample, a plug coupling is shown in U.S. Pat. No. 5,647,751. Accordingto the state of the art, female plug couplings consist of a two-partplastic material body in which the crimp connection pins for theconductor ends are inserted. The conductor ends are crimped on, i.e.,fixed on, to the crimp connection pins and, the insert isextrusion-coated and thus forms the core of a grip body. The face sideof this grip body has three plug openings arranged in a triangle to oneanother in a complementary manner to the contact pins of the connectorplug. One of the connector plug contact pins is round, and the other two(current conducting) contact pins are rectangular.

In the manufacturing of the inserts for the plug coupling, problems havearisen in connection with the crimping-on of the conductor ends to theeffect that it has proved difficult to perform the working step CRIMPINGwith a simple tool in a single operation. By reason of the arranging andassigning of the crimp connection ends in different topological planes,there is involved on the one hand a complicated tool and, on the otherhand, different and in part diametrical force directions.

SUMMARY OF THE INVENTION

The present invention provides a plug coupling in which all the crimpconnections lie in one and the same plane and which, therefore, can beexecuted in one operation with a simple one-piece tool.

In this regard, the special form of execution chosen for the crimpconnection of the ground conductor has additionally proved to beespecially advantageous, as the plugging force for the correspondingcontact pin of the connector plug is relatively slight because of theshortness of the contact length of the plugging path. Both for thecurrent conductor contact pins, and also for the protective conductorcontact pin, there have been provided on the corresponding parts of theplug, coupling lugs or lashes which provide introduction aids.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention is explained in the following with the aid of thedrawings, wherein:

FIG. 1 is a representation of an exemplary base body;

FIG. 2 illustrates the crimp connection pins for the current conductorsand the ground conductor to be installed in the base body illustrated inFIG. 1 next to one another;

FIG. 3 illustrates the base body according to FIG. 1, with the crimpconnection pins according to FIG. 2 installed therein;

FIG. 4 provides an outside view of a cover cap of the insert of thepresent invention;

FIG. 5 provides an inside view of the cover cap according to FIG. 4;

FIG. 6 illustrates a complete insert for a plug coupling composed of thebase body according to FIG. 1, with the crimp connection pins positionedtherein as illustrated in FIG. 3, and of the cover cap according to FIG.4 and FIG. 5;

FIG. 7 illustrates the installation according to FIG. 6 with the covercap removed to illustrate a crimped-on supply line; and

FIG. 8 illustrates a finished plug coupling including the insert of thepresent invention.

DETAILED DESCRIPTION OF THE INVENTION

In FIG. 1 there is represented a base body 1 made of hard elasticplastic material. Base body 1 includes three incisions 2 for theinstalling of the crimp connection pins 30, 31 (see, e.g., FIGS. 2 and3). Opposite incisions 2, base body 1 includes a face wall 5, whichabuts raised edges 6, 7 of the base body 1. The base body 1 has aplurality of molded-on pins 8 and columns 9 and further includesseparated insertions channels 11, 12, 13 formed between the front edgeof base body 1 (i.e., the edge having incisions 2 formed therein), andface wall 5. Opposite the face wall 5 there are molded two highercolumns 14, 15, the importance of which will be described later.

In the face wall 5, in the lower zone adjacent to the base bottom 16,there are provided two rectangular passage openings 17, into which thecurrent conductor contact pins of the connection plug are introduced. Inthe upper zone there is provided a passage opening 18 for the roundcontact pin (ground pin) of the connector plug.

FIG. 2 shows, next to one another in quasi-assembled position, a crimpconnection pin 30 for a current conductor, a crimp connection pin 31 forthe ground conductor, and a (second) crimp connection pin 30 for thesecond current conductor. Each crimp connection pin 30 consists of ametal strip bent in U-form, in which at one end there are formed a pairof crimping claws 19, 20, and at the other end a pair of laterallyspaced lugs 21. Lugs 21 receive the rectangular contact pins of theconnecting plug and serve as an introduction aid therefor. The distancebetween the U-shaped shanks of the metal strip is chosen in such mannerthat the rectangular current conductor contact pins of the connectorplug are engaged snugly and with force-closure, i.e. have contact.

The crimp connection pin 31 for the ground conductor is designedaccording to the preferred example represented in FIG. 2 as an L-shapedmetal part, having a leg thereof formed from a U-shaped metal strip sothat, as with the crimp connection pins 30, there results a U-shapedmetal strip 22 with a pair of crimping claws 23, 24. The second leg, orbase of the L-shaped crimp connection 31 is formed by two webs 25extending from the U-shaped leg. The two webs 25 spring against oneanother and include receiving claws 26 for the round contact pin of theconnector plug. The spacing of receiving claws 26 to one another ischosen in correspondence to the diameter of the round contact pin, i.e.,the ground conductor. On one side of the receiving claws 26, facing awayfrom the crimping claws 23, 24, there is formed in each case anobliquely outwardly directed lash 27 which facilitates introduction ofthe protective conductor contact pin. Because of the only slight contactlength of the contact pin inside the receiving claws 26 of the parallelwebs 25, only a relatively slight plugging force is required.

In order to prevent the possibility that, for example, a connection plugmay be inserted with too thick a protective conductor contact pin, thereceiving claws 26 include cross webs 26′. Cross webs 26′ cooperate withcomplementary stops 29 (in the interior of the cover cap 28) to preventoverstretching of receiving claws 26.

The “cross section form,” i.e., the form of the crimp connection pin 31for the protective conductor contact pin also may be other thanL-shaped; there is also thinkable a Z-form or the like, for example.

In FIG. 3, the crimp connection pins 30 and 31 are positioned in basebody 1. The two laterally lying crimp connection pins 30 lie in theinsertion channels 11, and 13 formed from the molded-on pins 8 andcolumns 9, 14, 15 and crimping connection pin 31 lies in the middleinsertion channel 12. The crimping connection pin 31 is supported by itstwo resilient webs 25 between the higher columns 14, 15 lying oppositethe face wall. The receiving claws 26, molded on the upright webs 25 ofthe L-shaped crimp connection pin 31, lie opposite the passage opening18 in the face wall 5.

FIG. 4 and FIG. 5 show a cover cap 28 complementary to the base body 1,which cap is so constructed that it closes over the incisions 2 for thecrimp connection pins 30, 31, stands upright on the raised edges 6, 7and abuts the periphery of face wall 5. In this way, the interior spaceof insert 50 is protected against the plastic injected into an injectionmold to form a complete receptacle. As mentioned with the aid of FIG. 2,the cover cap 28 has on its inside two stops 29 complementary to thecross webs 26′ of the receiving claws 26 of the crimp connection pin 31,which stops protect the receiving claws 26 against an overstretching.Stops 29 are connected, via a cross web 29′, to the ends of receivingclaws 26 away from the face side of the cover cap 28, wherewith asupport against tilting is ensured for the receiving claws 26, in theinserting of the connector plug.

According to the representation in FIG. 6, the cover cap 28 is emplacedor clipped on the base body 1, so that now there is present a closedbody/insert 50. To the outside there stand out only the spired crimpclaws 19, 20, and 23, 24, of the crimping connection pins 30, 31,respectively. The representation in FIG. 6 shows the assemblage state inwhich the strands of a supply line are laid in and the crimping tool isapplied.

FIG. 7 shows the body/insert 50 with a crimped-on supply line 51 inwhich, for reasons of perspicuity, the cover cap 28 is not shown in thedrawing. The three strands 52, 53, 54 of this supply line are crimpedaccording to their respective allocation with the crimp connection pins30, 31. According to the present invention, strands 52, 53, 54 of supplyline 51 are crimped to connection pins 30, 31 with a one-piece crimpingtool which “rolls up,” i.e., crimps with form and force closure, thestrand connections 52, 53, 54 of the supply line 51, that lie in one andthe same plane with the crimp connection pins 30, 31 lying in the sameplane, i.e., the working plane.

With the aid of FIG. 8 there is to be shown the end product “PLUGCOUPLING.” The insert/body 50 joined with the supply line 51 isinjection-molded from soft-elastic plastic material, so that thereresults a finished plug coupling 60. This has on its quasi face sideformed by the face wall 5, the three through openings 17, 18 (describedabove in connection with FIG. 1) into which the complementary contactpins of an apparatus plug can be inserted, wherewith then the connectionwith the current supply mains can be established.

What is claimed is:
 1. An insert for a female plug coupling having threeplug openings accommodating two current conductors and a groundconductor of a male plug coupling, the insert comprising: a receivingbody; a plurality of crimp connection pins for the two currentconductors and the ground conductor, said crimp connection pinspositioned in said receiving body; a cover cap emplaced on the receivingbody after the crimp connection pins are positioned in the receivingbody, wherein the current conductors and the ground conductor arearranged relatively to one another in a triangle, characterized in that:the receiving body comprises a base body having an upright-standing facewall and a plurality of insertion channels for receiving the crimpconnection pins for the current conductors and the ground conductor,crimp connections of the crimp connection pins for the currentconductors and the ground conductor being substantially coplanar whensaid crimp connection pins are received in said insertion channels, andwherein the face wall has a plurality of passage openings arranged incorrespondence with the relative arrangement of the current conductorsand the ground conductor, in such manner that the passage openings forthe current conductors are adjacent to a base of the base body and thepassage opening for the ground conductor has a pair of resilientreceiving claws for engaging the ground conductor of the male plugcoupling.
 2. Plug coupling according to claim 1, characterized in thatthe crimp connection pin for the ground conductor is constructed inL-shape, wherein the L-shaped crimp connection for the ground conductorincludes a first leg parallel to the crimp connection pins for thecurrent conductors, and wherein the L-shaped crimp connection for theground conductor includes a second leg in the form of two parallel websprotruding from the first leg and running parallel to the face wall,said second leg including said pair of resilient receiving claws forengaging the ground conductor of the male plug coupling.
 3. Plugcoupling according to claim 1, characterized in that each crimpconnection pin for the current conductors comprises a U-shape bent metalstrip, in which the spacing of the U-shaped shank corresponding to thethickness of the current conductors of the male plug coupling is chosenin such manner that the current conductors lie against the U-shapedshanks.
 4. Plug coupling according to claim 3, characterized in thateach crimp connection pin for the current conductors includes alaterally spaced protruding lug adjacent the passage openings for thecurrent conductors.
 5. Plug coupling according to claim 2, characterizedin that the first leg of the crimp connection pin for the groundconductor comprises a U-shape bent metal strip, and wherein the parallelwebs and resilient receiving claws of the second leg of the crimpconnection pin for the ground conductor have a spacing chosen incorrespondence to the size of the ground conductor of the male plugcoupling in such manner that the ground conductor lies against thereceiving claws.
 6. Plug according to claim 5, characterized in that thereceiving claws have lash plates obliquely protruding from the passageopening for the ground conductor.
 7. Plug coupling according to claim 1,characterized in that the receiving claws each include a cross web, andwherein the cover cap includes a stop corresponding to each cross web,whereby each cross web cooperates with the corresponding stop to limitmovement of the parallel webs of the second leg of the crimp connectionpin for the ground conductor so that in the inserting of the connectorplug the receiving claws are protected against overstretching.
 8. Plugcoupling according to claim 7, characterized in that the stops areconnected by a cross stop abutting the stops, said cross stop positioneda distance from the face wall.
 9. Plug coupling according to claim 2,characterized in that each crimp connection pin for the currentconductors comprises a U-shape bent metal strip, in which the spacing ofthe U-shaped shank corresponding to the thickness of the currentconductors of the male plug coupling is chosen in such manner that thecurrent conductors lie against the U-shaped shanks.
 10. Plug couplingaccording to claim 9, characterized in that each crimp connection pinfor the current conductors comprises a U-shape bent metal strip, inwhich the spacing of the U-shaped shank corresponding to the thicknessof the current conductors of the male plug coupling is chosen in suchmanner that the current conductors lie against the U-shaped shanks. 11.Plug coupling according to claim 2, characterized in that the receivingclaws each include a cross web, and wherein the cover cap includes astop corresponding to each cross web, whereby each cross web cooperateswith the corresponding stop to limit movement of the parallel webs ofthe second leg of the crimp connection pin for the ground conductor sothat in the inserting of the connector plug the receiving claws areprotected against overstretching.
 12. Plug coupling according to claim3, characterized in that the receiving claws each include a cross web,and wherein the cover cap includes a stop corresponding to each crossweb, whereby each cross web cooperates with the corresponding stop tolimit movement of the parallel webs of the second leg of the crimpconnection pin for the ground conductor so that in the inserting of theconnector plug the receiving claws are protected against overstretching.13. Plug coupling according to claim 4, characterized in that thereceiving claws each include a cross web, and wherein the cover capincludes a stop corresponding to each cross web, whereby each cross webcooperates with the corresponding stop to limit movement of the parallelwebs of the second leg of the crimp connection pin for the groundconductor so that in the inserting of the connector plug the receivingclaws are protected against overstretching.
 14. Plug coupling accordingto claim 5, characterized in that the receiving claws each include across web, and wherein the cover cap includes a stop corresponding toeach cross web, whereby each cross web cooperates with the correspondingstop to limit movement of the parallel webs of the second leg of thecrimp connection pin for the ground conductor so that in the insertingof the connector plug the receiving claws are protected againstoverstretching.
 15. Plug coupling according to claim 6, characterized inthat the receiving claws each include a cross web, and wherein the covercap includes a stop corresponding to each cross web, whereby each crossweb cooperates with the corresponding stop to limit movement of theparallel webs of the second leg of the crimp connection pin for theground conductor so that in the inserting of the connector plug thereceiving claws are protected against overstretching.